Giant-size toy block



Filed June 11, 1952 ,Jose ah John L United States Patent i GIANT-SIZE TOY BLOCK John L. Joseph, Hasbrouck Heights, N. J. Application Tune 11, 1952, Serial No. 292,839

4 Claims. (Cl. id -24) The present invention relates to a novel construction for a toy block such as may be used by children, and in particular to the construction of such a block of extra large size. I

The use of blocks of various types in the entertainment and training of children is wide-spread. Most blocks are of comparatively small size, having dimensions on the order of two or three inches, the blocks being sold in sets of a plurality of blocks in order that the child might have sufiicient units at hand to build real or imaginary structures of various types. Blocks of this normal size suffer from the disadvantage that they require considerable manipulative skill in order to be worked with, the structures produced by them are flimsy and insubstantial, and the dimensions of those structures are necessarily quite limited.

Educators have long recognized the desirability of providing large blocks having a length on the order of a foot or so and the other dimensions of which are correspondingly much greater than those of the conventional small blocks. With large blocks of this type the 7 child is able much more expeditiously to produce structures of a size comparable to his own, such structures being useable as such by the child. For example, the child can, with blocks of large size, readily produce a representation of an airplane in which the child may sit, as shown in Fig. 1. The entertainment and educational value of such blocks is self-evident.

Blocks of this large size have been produced in the past, both in wood and in plastic, but because of the manufacturing diificulties involved, and because the blocks must be light enough to be readily handled by a child and not constitute a hazard to the child should they fall upon him, blocks of this size customarily cost five dollars or more per. block. Consequently, use of blocks of this size has been limited to nurseries or kindergartens which can alford the monetary outlay involved. The cost of blocks of this size has precluded their use in the home, since there are few households which will spend fifty dollars or more for only ten blocks, and at least that number of blocks is generally required if a set of blocks is to be gainfully used.

The present invention relates to a block construction which will make blocks of this size readily available even to an individual household of limited means. To that end the blocks in question are formed from corrugated paperboard or the like, cut and scored into blanks which may readily be erected. In order to provide blocks of sufficient rigidity and strength to hold their shape if the child should sit, stand or even jump upon them, which usage is not only expected but is even encouraged by the size of the blocks and the uses to which they may be put, the blocks are rigidified and'strengthened by means of interlocking partitions, also preferably of corrugated paperboard orsimilar structurally strong material, which are snugly received within the blocks, these partitions also being formed in blanks.

2,751,105 Patented June 26, 1956 It is desirable that the blocks have smooth and regular outer surfaces on all sides, so that the blocks may be stacked one upon the other. It is also necessary that the blocks, when erected, be securely locked in erected condition so as to be able to withstand the use, and even the abuse, to which they may be subjected without coming apart or collapsing. To accomplish this, one or more sides and ends of the blocks are defined by wall sections which snugly meet one another and which have flaps which are bent into the block and which interlock with the partitions, being enterable into slots provided in those partitions for that purpose. The locking fiaps are snugly and frictionally received within the slots in the partitions, thus preventing their withdrawal, and the inherent rigidity of the material of which the wall sections and flaps are formed also prevents unfolding of the blocks, since distortion of the wall sections or the flaps must accompany withdrawal of the locking flaps from the partition slots.

Where theedges of the wall sections meet, visible seams are defined, having the appearance of a line along the length of the wall which is formed by the sections. It is preferred to have this seam located substantially centrally of the height of that wall, and to have the seams formed in three contiguous walls in line with one another, so that when the blocks are used in simulating a building or the like, and if the seamed walls of the block are visible, each block will give the appearance of being constituted by a pair of bricks or the like. In this way very pleasing decorative effects may be produced. When, as is here specifically illustrated, one side Wall and a pair of opposed end walls are thus seamed, a line may be drawn on the other side wall or walls of the block in line with the aforesaid seam so as to give the sides and ends of the block a uniform appearance no matter from what angle it may be viewed. The formation of such an artificial line is optional, and it might even be preferred to leave the unseamed side wall or walls unmarked, thus enabling the user, through choice of position of the block, to achieve different visual effects.

If a uniform and unseamed appearance is desired, the seamed Walls may be covered by a strip of paper tape or the like, the outer surface of which is decorated and/ or colored so as to conform to or decoratively contrast with the exposed surfaces of the block. These strips will also function to retain the block shell in erected condition, and will hide the exposed edges of the meeting wall sections.

The blocks of the present invention may, of course, be sold in erected condition, but by reason of their novel structure they are particularly adapted to be sold in the form of kits, each kit consisting of a plurality of sets of blanks from which the block shell and interlocking partitions are formed, together with appropriate strips, preferably pre-cut to length, of gummed paper tape or the like, if such paper is used to retain the seams of the block in closed condition and to cover the side and end walls of the block. Since these blanks, and the paper or tape strips if used, are all flat, a set suitable for the production, for example, often blocks will take up only a fraction of the space. that the blocks themselves will assume, and thus the kits may be handled and sold by retail outlets without presenting any appreciable problem insofar as storage or display space is concerned. By reason of the simplified construction of the blocks and the careful design of the blanks, by reason of which the blocks may be erected in a simple manner by any adult without the exercise of any particular skill, sale of the blocks in the form of such kits is entirely feasible.

To the accomplishment of the above, and to such other objects as may hereinafter appear, the present invention relates to the structure of a toy block, and particularly such a block of appreciable size, as defined in the appended claims and as described in this specification, taken together with the accompanying drawings in which:

' Fig. l' is a perspective view showing onemanner of use of the blocks of the present invention, illustrating the blocks assembled to simulate an airplane in which the youthful builder himself may sit and pilot;

Fig. 2 is a top plan view of the'erected block, but'with a portion of the top wall thereof broken away;

Fig. 3 is across sectional view taken along the line 33 of Big. 2;

Fig. 4 is a cross sectional view taken along the line Fig.5 is a topplan view of the block shell is formed;

Fig. 6 is a top plan view of a blank from which the partition members are formed, theblank specifically shown blank from which the including two sets of partition members;

Fig. 7 is a detailed perspective view showing the relation between the direction of corrugation of the paperboard employed and the dimensions of the block; and

Fig. 8 is a transparent view of the block shell in erected condition but without the partitions therein, Fig. 8 also 7 illustrating the manner in which a strip of paper tape or the like may be applied along the seamed walls of the block so as to hide those seams from view.

The blocks of the present invention, which may, for example, have a length of 12 inches, a width of 6 inches and a height of 4% inches, may be formed of any suitable sheet material having sufficient strength and Wear resistance which may be folded or bent into erected or assembled condition. Corrugated paperboard is preferred for reasons of lightness and expense, but other similar materials could also be'used. The block comprises an outer shell A formed from the blank of Fig. and an internal reinforcing and rigidifying structure formedv from the blank of Fig. 6 and defined by the longitudinal partition members B and the transverse partition members B interlockable with one another and snugly receivable within the shell A.

Having reference first to Fig. 5, the shell A is formed from a single blank cut with only a minimal amount of waste from a considerably more extensive sheet of corrugated paperboard or the like and provided with cuts and folds defining the various structural portions of the shell A. More specifically, the blank comprises a first side wall 2 having fold lines 4 and 6 at its top and bottom 1 edges respectively 'by means of which top wall 8 and bottom wall 10 of the. box are secured to the. side wall 2. Side Wall sections Hand 14 are secured to the upper and lower edges respectively of the top and bottom Walls 8 and Why means offold lines 16 and 18 respectively. Locking fiaps '20 and '22 are secured to the upper edges of the side wall sections 12 and the lower edge of the side wall sections 14 respectively by means of fold lines 24 and 26 respectively. The sidewall sections 112 and 14 are here shown as equal in height, the height of each being onehalf the height of the side wall 2 so that the combined heights of the side wall sections 12 and 14 will equal the height of the side wall 2.

End wall sections 28 and 30 are secured to the end edges of the top wall '8 by means of fold lines 32 and 34 respectively, and end wall sections 36 and 38 are correspondingly secured by means of fold lines 40 and. 42 respectively to the end edges of the bottom wall 10. Locking flaps 44, 46, 43 and are secured to the free edges of the end wall sections 28,, 30, 36 and 38 respectively by' means of fold lines 52, 54, 56 and 58, respectively. The end Wall sections 30 and 38. and the end wall sections 28. and 36 define opposed pairs of end wall sections, the combined height of each pair of end wall sections being equal to the height of the sidewall 2, As

herespecifically disclosed, each of the individual end wall 2 via fold lines 64 and 66 respectively, the flaps 60- and 62 being separated from the adjacent end Wall sections by means of cuts 68. Each of the flaps 60 and 62 is provided with a slot 70 positioned midway of its length, for a purpose hereinafter to be described.

If further rigidifying is desired, flaps 74 may be provided at the end edges of the side wall sections 12 and 14, being connected thereto by means of fold lines 76 and separated from the adjacent end wall sections by means of cuts 78.

Having reference now to Fig. 6, the longitudinal and transverse partition members B and B are also cut substantially without waste from an extensive sheet of corrugat'ed paperboard or the like, the length of the longitudinai partition members B being substantiallyequal to the internal length of the shell A, and the length of the transverse partition member B being substantially equal to the internal width of the shell A. As here'disclosed each shell A is adapted to contain a pair of spaced longitudinal partitions B and three spaced transverse partition mem-- production of the partition members, and also in order to facilitate packing of the blanks intofkits, it is contemplated that two sets of partition members will be formed in a single blank, the partition members being separated by cuts indicated by the solid lines in Fig. 6 but temporarily held together by means of the narrow and easily tearable tabs 86. End edges of the longitudinal partition members B and one end edge of the transverse partition members B. are provided with slots 88 and-90 respectively, these slots being positioned centrally of the height of the partition members B and B, having a width closely equal to twice the thickness of the locking tabs 20, 22, 44, 46, 48 and 58, and having a depth, substantially equal to the height of said locking flaps, all for a purpose hereinafter to be described.

The preferred method of erecting a block from the blank of Fig. 5 and the partition members of Fig. 6 is as follows: Two longitudinal partition members B and three transverse partition members B are first separated from the blank of- Fig. 6 and interlocked. They are then placed in position on the bottom wall 10 of the blank of Fig. 5' between the fold li'nes'6, 18,-40and '42. The

side wall 2 is bent around the fold line 6 so as to eX-,

tend vertically and the top wall 8 is bent around the fold line 4 so as to lie on top of the partition members I B and B. The side wall sections 12 and 14 are then bent around the fold lines 16 and 18 respectively so as to cover the exposed front of the partition assembly, the

' where the locking flaps 20' and 22 are bent inwardly, so

. as to define 'a visible seam 92. a V

The flaps 74', if. present, are bent'around the fold line 76 so as to partially cover the exposed ends of the longitudinal partitions 13,. and the flaps 60 and 62 are bent around the fold lines; 64 andrespectively soas o cover 74 being substantially equal to the width of the block so that the end surfaces of the partition assembly will substantially completely be covered. Next each pair of end wall sections 30, 38 and 28, 36 are bent around the fold lines 34, 42 and 32, 40 respectively so as to define the end Walls of the block shell A, their locking flaps 46, 50, 44 and 48 respectively being bent around the fold lines 54, 58, 52 and 56 respectively so as to pass between adjacent flaps 74 and through the slots 70 formed in the flaps 60 and 62 and so as to enter the end edge slots 83 formed in the longitudinal partition members B, there being snugly received. The meeting edges of the opposed pairs of end wall sections 30, 38, 28 and-36 where their respective locking flaps extend inwardly, meet to define seams 94. The locking flaps 20, '22, 44, 46, 48 and 50 serve to hold the block shell in erected condition, not only by reason of their snugness within the slots 88 and 91), the width of those slots being substantially equal to the combined thicknesses of the locking flaps received therein, but also by reason of the fact that some distortion of the locking flaps and the wall sections to which they are secured is necessary if the locking flaps are to be removed from the slots, and the inherent structural strength and rigidity of the material from which the shell is formed militates against any such distortion.

The seams 92 and 94, in the form here specifically disclosed, occur on one side wall and on two contiguous end walls of the block. The other side wall, the side wall 2, is unseamed. If it is desired that the block should have a uniform appearance on all sides, a line may be artificially drawn on or impressed into the outer surface of the side wall 2 in line with the seams 92 and 94. Conversely, if it is desired to hide all of the seams from view, a covering strip 96 (see Fig. 8) of paper or the like may be adhesively secured to the walls defined by the side and end wall sections so as to cover. the seams 92 and 94 and, preferably, so as to cover the entire side walls defined by those sections. The outer surface of the strip 96 is colored or decorated to blend or harmonize with, or if desired to contrast with, the appearance of the exposed outer surfaces of the top and bottom walls 8 and 10. For purposes of convenience and uniformity it will probably generally be desired, when such a strip 96 is employed, to have it extend around the outside of the side wall 2 as well.

in order to provide maximum strength to the box in the direction of its width or thickness, it is preferred, as illustrated in Fig. 7, that the corrugations, when corrugated paperboard is employed, should extend parallel to those directions and hence perpendicular to the length of the box. This orientation of the corrugations is preferred because if a child should apply his weight to the box, as by sitting or jumping on it, that weight is most likely to be applied to the top or bottom walls 8 or or to the side walls 2 or 12, 14, rather than to the end walls 30, 38 or 28, 36, and if pressure should be applied to the end walls 30, 38 or 28, 36, the flaps 60, 62 and 74, defining a reinforcing double ply at the end walls, will give those walls added strength. Moreover, this orientation of the corrugations in the shell blank permits accurate location of the fold lines 4, 6, 16 and 13, thus ensuring the production of blocks characterized by uniformity and regularity.

It will be noted from the orientation of the longitudinal partitions B and transverse partitions B in the blank of Fig. 6 that when said partitions are formed of corrugated paperboard or the like the corrugations will run in opposite directions with respect to the length of those partitions. For example, if the corrugations should run vertically in Fig. 6, they would extend through the longitudinal partitions B in the direction of their width, so that those partitions will provide extra strength to the block in the direction of the height of the block, and through the transverse partitions B in the direction of their length, so that those partitions B will provide ex- 3 ceptional strength to the block in the direction of the width of the block. In this way one set of partitions or the other will be oriented with its direction of maximum strength in such a direction as to resist the most likely pressures and forces to which the block will be subjected In use.

It will be apparent from the above description that playing blocks of appreciable size can be produced according to the teachings of the present invention in an extremely inexpensive manner, thus permitting the use of such giant blocks, the educational value of which is well recognized, in very home with a child, instead of restricting their use, as has been the case heretofore, to kindergartens, play schools and other group organizations. Moreover, because the giant blocks of the present invention can be readily erected from flat blanks, any potential resistance on the part of the retailer to the stocking and selling of such blocks, based upon the space which the erected blocks must occupy, is effectively avoided. The blocks are light, may be readily manipulated even by a young child, and will not represent a source of danger to the child should a pile of such blocks fall upon him. The blocks, when constructed of appropriate material, will exhibit satisfactory resistance to wear and abrasion, and the strength of the blocks will be more than adequate to withstand any reasonable forces to which they may be subjected. To illustrate, blocks constructed according to the present invention from conventional corrugated paperboard have been repeatedly jumped upon by an adult without any visible deformation or damage whatsoever. Kits consisting of an appropriate number of shell-forming blanks, a corresponding number of partition members, and if desired, covering strip material, preferably precut into appropriate lengths, can be readily packaged so as to take up a small amount of room and thus may be readily stored and handled in the process of distribution and just as readily transported by the ultimate purchaser. By reason of the simplicity of the block structure the blanks may be assembled and erected by any individual upon the exercise of merely a moderate amount of care and without requiring any special skill or training so as to define uniform and square cornered blocks with smooth faces.

While but one embodiment of the present invention has been here illustrated, it will be apparent that many de tailed variations may be made therein without departing from the spirit of the invention as defined in the following claims.

I claim:

1. A toy block comprising a shell formed from sheeted paperboard of substantial strength and longitudinal and transverse partition members of substantial structural strength having dimensions substantially equal to the internal dimensions of said shell and snugly received within the interior thereof, said shell comprising a first side wall, top and bottom walls secured respectively to the top and bottom edges of said first side wall and each having a free side edge, side wall sections secured to the free side edges respectively of said top and bottom walls, the combined heights of said side wall sections equalling the height of said first side wall, said side wall sections being bent up to meet and define a second side wall, flaps secured to the meeting edges of said side wall sections, end wall sections secured to the end edges of said top and bottom walls so as to define opposing pairs of end wall sections, the combined heights of each opposing pair of end wall sections equalling the height of said first mentioned side wall, each opposing pair of end wall sections being bent up to meet and define end walls, and flaps secured to the meeting edges of said end wall sections, the end edges of said partition members adjacent said side and end wall sections having slots aligned with the meeting edges of said sections and into which the flaps secured to said sections are received so as to lock said block in erected condition.

ass-1510s 2. A toy block comprising a; shell formed from: sheeted paperboard of substantial strength and longitudinal; and. transverse partition members, of substantial structural strength having dimensions. substantially equalto the irr-- ternal' dimensions of said shell and snugly received within the interior thereof, said shell comprising a first side wall, top and bottom walls-secured respectively: to the top and bottom edges. of said first'side wall and. eachhavingaa free side edge, side wall sections secured to the free side edges respectively of said top and bottom Walls, the combined. heights of said side wall sections equalling the height of said first side Wall, said sidewall sections being bent up to meet and define a second side wall,.fiaps: secured to the meeting edges ofv and extending substantially'the; length. of. said side wall sections, endwal'l sectionssecured-to the" end. edges of said top and. bottomwalls so as to defineopposing pairsof end. wall. sections, the combined. heights of. eachopposing pair of end. wall sections equalling theeight of said. first side wall, each. opposing pair of end wallsections being bent up. to meet and. define end walls, audflapssecuredto the meeting edges of and extendingsubstantially the length of said end wall. sections',,the.end edges of said partition members adjacent said side and end. wall sections having slotsaligned with the edges of the meeting sections and. into which the flaps secured to said sections are received so as to lock said block in. erected condition.

3. A toy block comprising a. shell formed from sheeted paperboard'of substantial strength and longitudinal and transverse partition members of substantial structuralstrength having dimensions substantially equal to the internal dimensions of said shell and snugly received within the interior thereof, said shell comprising a first sidewall,

top and bottom walls secured respectively to the top and. bottom edges of said first side Wall and each having a free side edge, side Wall sections secured to the freeside edges respectively of said top and bottom walls, the

combined heights of said side wall sections equalling the height of said first side Wall, saidside Wall sections being bent up to meet and define a second" side wall, flaps secured. to the meeting edges of said sidewall sections,

and wall sections secured to theend edges of said top and bottom walls so as to define opposing pairs of' end wall sections, the combined heights of eachopposingsecured to the end edges ofi said. first mentioned side wall and provided: withslots which; register with the. fiaps on" saidend wall sections anduthr ough; which said flaps 'arepassed, the end edges of said partition members adjacent said side and end wall. sections having slots alignedwith the meeting edges; of said sections and; into which. the. flaps secured to said sections are received so as to lock said block inerected condition, V j

4. A. toy block. comprising a shell formed frornsheeted.

paperboard of substantial strength and longitudinal and. transverse partition members 013 substantial structural strength havingdimensions substantially equal tothe in:-- ternal dimensions of said shell and snugly received. within theinterior thereof,.said shell comprising a first sidewall,

top and bottom; Wall's;securedlrespectively to the top and 7 bottom edges of said first side wall; and each having a free side edge, sidewall sections secured to the free:

heights ofeaclropposing pair of end wall sections equalling the height of saidfirst side wall, each opposing pair of end. wall sections being bent up to meet and define end walls, flaps secured tothe: meeting edges of and extend ing substantially. the length of said end wall sections, and

flaps secured to the end edges of said first side wall and i provided with slots extending through substantially the entire widththereof which register. with the flaps on said;

end wall sections and through which said flaps are passed,

the end. edges of said partition members adjacent said" side andend wall sections having slots aligned with the meeting edges of said sections and into which the flapssecured. to said sections are received so as to lock said block in erected condition. 7

ReferencesCited in the file of this. patent UNITED STATES: PATENTS 1,237,728 Tilck Aug. 21, 1917: 1,976,530 Verhoven -Q. Oct. 9, 1934 2,423,332 Mayer July 1, 1947 2,527,221 Huye ...L Oct. 24, 1950 2,648,483, Belsinger Aug. 11, 1953; 

